Interior or exterior rearview mirror assembly

This application claims priority to U.S. Ser. No. 60/878,314 titled EXTERIOR PRISMATIC DOOR MIRROR, filed Dec. 31, 2006, which is incorporated herein by reference.

I. BACKGROUND OF THE INVENTION

A. Field of Invention

This invention pertains to the art of methods and apparatuses regarding mirror assemblies, and more specifically to methods and apparatuses regarding a mirror assembly for a vehicle.

B. Description of the Related Art

It is known in the art of automotive mirror assemblies to provide a first mirror piece consisting of a sheet of glass having a metallic coating and a second mirror piece consisting of a plastic back piece. The second mirror piece serves as a housing. The first mirror piece is then attached to the second mirror piece, typically with an adhesive pad. The mirror assembly, consisting of both the first and second mirror pieces, is then attached to the interior or exterior of a vehicle.

While such known mirror assemblies work well for their intended purpose, improvements are greatly desirable. One desirable improvement would be to make a mirror assembly more light weight. Another would be to improve the manufacturability by eliminating the assembly step required to attach the first mirror piece to the second mirror piece. Still another desirable improvement would be to improve the tolerance of curvature. Yet another desirable improvement would be to increase the styling freedom in choosing a mirror shape and/or curvature.

The present invention is simple in design and provides the improvements noted above. The limitations and difficulties inherent in the art are therefore overcome in a way that is simple and efficient, while providing better and more advantageous results.

II. SUMMARY OF THE INVENTION

According to one embodiment of the invention, a vehicle comprises a vehicle frame, an engine supported to the vehicle frame, at least one ground engaging wheel supported to the frame and operatively connected to the engine to provide locomotion to the vehicle, a vehicle body supported to the frame and defining a passenger compartment, and a mirror assembly supported to the vehicle.

According to another embodiment of the invention, a mirror assembly comprises a middle portion having a first side, a second side, and a perimeter, wherein the first side comprises a reflective portion. A front portion is substantially transparent and is formed by injecting a first thermoplastic material into a mold on the first side of the middle portion. A back portion is substantially opaque and is formed by injecting a second thermoplastic material into the mold on the second side of the middle portion. The front portion and the back portion together substantially encompass the perimeter of the middle portion.

According to another embodiment of the invention, the mirror assembly further comprises a scratch resistant material covering at least a portion of the front portion.

According to another embodiment of the invention, the middle portion of the mirror assembly further comprises a heater member on the second side of the middle portion.

According to still another embodiment of the invention, the first thermoplastic material is a first polycarbonate material and the second thermoplastic material is a second polycarbonate material.

According to another embodiment of the invention, the is back portion is formed within the mold to have a first attachment portion for use in attaching the device to a vehicle.

According to yet another embodiment of the invention, a method of forming a mirror assembly comprises the steps of (a) inserting a middle portion into a mold, wherein the middle portion comprises a first side having a reflective portion, a second side, and a perimeter, (b) inserting a first thermoplastic material into the mold to form a front portion on the first side of the middle portion, wherein the front portion is substantially transparent when the mirror assembly is used, and (c) inserting a second thermoplastic material into the mold on the second side of the middle portion to form a back portion, wherein the back portion is substantially opaque when the mirror assembly is used, and wherein the front portion and the back portion together substantially encompass the perimeter of the middle portion.

One advantage of this invention is that mirror assemblies can be made smaller as there is no longer a need for a holding edge.

Another advantage of this invention is that mirror assemblies can be made with reduced weight.

Another advantage of this invention is that the process for making mirror assemblies can be simplified.

Yet another advantage of this invention is that designers of mirror assemblies can have additional styling freedom for varying mirror shapes and curvatures.

Still another advantage of this invention is that the assembly step required to attach the first mirror piece to the second mirror piece can be eliminated.

Still other benefits and advantages of the invention will become apparent to those skilled in the art to which it pertains upon a reading and understanding of the following detailed specification.

III. BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take physical form in certain parts and arrangement of parts, embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein:

<figref idrefs="DRAWINGS">FIG. 1</figref> is a side perspective view of a vehicle equipped with an exterior mirror assembly according to one embodiment of this invention.

<figref idrefs="DRAWINGS">FIG. 2</figref> is a side perspective view of a vehicle interior showing an interior mirror assembly according to another embodiment of this invention.

<figref idrefs="DRAWINGS">FIG. 3</figref> is a side perspective view of a vehicle exterior showing an exterior mirror assembly according to another embodiment of this invention.

<figref idrefs="DRAWINGS">FIG. 4</figref> is a perspective view of a vehicle interior showing an interior mirror assembly according to another embodiment of this invention.

<figref idrefs="DRAWINGS">FIG. 5</figref> is a front view of a mirror assembly made according to one embodiment of this invention.

<figref idrefs="DRAWINGS">FIG. 6</figref> is a sectional view of the mirror assembly taken along line A-A in <figref idrefs="DRAWINGS">FIG. 5</figref>.

<figref idrefs="DRAWINGS">FIG. 6A</figref> is a sectional view of the mirror assembly taken along line A-A in <figref idrefs="DRAWINGS">FIG. 5</figref>.

<figref idrefs="DRAWINGS">FIG. 7</figref> is a sectional view of the mirror assembly taken from Detail Z in <figref idrefs="DRAWINGS">FIG. 6</figref>.

<figref idrefs="DRAWINGS">FIG. 8</figref> is a schematic view of vehicle.

<figref idrefs="DRAWINGS">FIG. 9</figref> is a front perspective view of a vehicle exterior showing a pair of exterior mirrors according to one embodiment of this invention.

<figref idrefs="DRAWINGS">FIG. 10</figref> is a schematic view of a mold that may be used according to one embodiment of this invention.

<figref idrefs="DRAWINGS">FIG. 11</figref> is a perspective view of an injection molding apparatus.

<figref idrefs="DRAWINGS">FIG. 12</figref> is a perspective view of an injection molding apparatus.

IV. DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein the showings are for purposes of illustrating embodiments of the invention only and not for purposes of limiting the same, <figref idrefs="DRAWINGS">FIG. 1</figref> shows a vehicle <b>10</b> equipped with an exterior mirror assembly <b>30</b> according to one embodiment of this invention and <figref idrefs="DRAWINGS">FIG. 2</figref> shows a vehicle <b>10</b> equipped with an interior mirror assembly <b>40</b> according to another embodiment of this invention. It should be noted that one or more exterior mirror assemblies <b>30</b> and one or more interior mirror assemblies <b>40</b> can be attached to the same vehicle. As shown in <figref idrefs="DRAWINGS">FIG. 8</figref>, each vehicle <b>10</b>, as is well known in the art, may include a frame <b>12</b>, a drive train including an engine <b>14</b> mounted to the frame <b>12</b>, and one or more ground engaging wheels <b>16</b> which are operatively attached to the frame <b>12</b> and are used to provide locomotion for the vehicle <b>10</b>. As shown in <figref idrefs="DRAWINGS">FIGS. 1-2</figref>, each vehicle <b>10</b> may also include a body <b>22</b> defining a passenger compartment <b>24</b>. One or more doors <b>26</b>, <b>28</b> may provide entry into the passenger compartment <b>24</b> in any manner known in the art. It should be understood that while the vehicles shown are passenger cars, this invention will work well with any vehicle including, but not limited to, cars, trucks, sport utility vehicles, cross-over vehicles, motorcycles, off-road vehicles, all-terrain vehicles, and airplanes as well as other passenger carrying devices such as boats. This invention may also work well in non-vehicle applications.

As shown in <figref idrefs="DRAWINGS">FIG. 3</figref>, the exterior mirror assembly <b>30</b> may extend from an outer surface of the vehicle <b>10</b> body <b>22</b> such as, in one embodiment, from either of the driver side door <b>26</b> or the passenger side door <b>28</b>. In another embodiment, as shown in <figref idrefs="DRAWINGS">FIG. 9</figref>, a separate exterior mirror assembly <b>30</b> may extend from each door <b>26</b>, <b>28</b>. The exterior mirror assembly <b>30</b> may be positioned near any one of the passenger compartment windows (or windshields) <b>32</b> so that the operator can easily view the exterior mirror assembly <b>30</b> from the driver's seat <b>34</b> in order to better view objects exterior to the vehicle <b>10</b>.

As shown in <figref idrefs="DRAWINGS">FIG. 4</figref>, the interior mirror assembly <b>40</b> may extend from an inner surface of the vehicle <b>10</b> body <b>22</b> such as, in one embodiment, from a ceiling <b>42</b> of the passenger compartment <b>24</b>, or in another embodiment, from a front windshield <b>44</b> of the passenger compartment <b>24</b>. The interior mirror assembly <b>40</b> may be positioned so that the operator can easily view the interior mirror assembly <b>40</b> from the driver's seat <b>34</b> in order to better view objects within or exterior to the vehicle <b>10</b>.

With reference now to <figref idrefs="DRAWINGS">FIGS. 5-7</figref>, each mirror assembly, whether exterior mirror assembly <b>30</b> or interior mirror assembly <b>40</b>, may include a front portion <b>50</b>, a middle portion <b>70</b>, and a back portion <b>90</b>. The front portion <b>50</b> may be formed of a substantially clear thermoplastic material. In one embodiment, the front portion <b>50</b> is formed from a substantially clear polycarbonate material, as will be discussed further below. The back portion <b>90</b> may formed of a substantially opaque thermoplastic material. In one embodiment, the back portion <b>90</b> is formed from a substantially opaque polycarbonate material. In another embodiment, the back portion <b>90</b> includes one or more integrated attachment features <b>80</b> for use in attaching the mirror assemblies <b>30</b>, <b>40</b> to the vehicle <b>10</b>.

With reference now to <figref idrefs="DRAWINGS">FIGS. 6-7</figref>, the middle portion <b>70</b> may include a reflective member <b>72</b> for use in reflecting light in a known manner. In a more specific embodiment, the reflective member <b>72</b> is generally planar in shape. In yet a more specific embodiment, the reflective member <b>72</b> is formed of a metallic film. In another embodiment, the middle portion <b>70</b> may include a heater member <b>76</b> for use in heating the mirror assemblies <b>30</b>, <b>40</b>. When used with an exterior mirror assembly <b>30</b>, the heater member <b>76</b> may be used to melt ice and snow from the front portion <b>50</b>. In one embodiment, the heater member <b>76</b> is formed of a heater film. In another embodiment, the middle portion <b>70</b> may include a protective member <b>74</b> for use in protecting the reflective member <b>72</b> from substantially direct contact with a heater member <b>76</b>. In one specific embodiment, the protective member <b>74</b> is formed of an insulated film. In another embodiment, the protective member <b>74</b> is formed of any insulating material chosen within sound engineering judgment. It should be understood that in one embodiment the middle portion <b>70</b> includes only the reflective member <b>72</b>. In another embodiment, the middle portion <b>70</b> may also include either the protective member <b>74</b> or the heater member <b>76</b>. In yet another embodiment, the middle portion <b>70</b> includes the reflective member <b>72</b>, the protective member <b>74</b>, and the heater member <b>76</b>. In a more specific embodiment using these three members, the middle portion <b>70</b> may include a three layer laminated film <b>78</b>. It should also be understood that in other embodiments the middle portion <b>70</b> may include other members.

With reference now to <figref idrefs="DRAWINGS">FIGS. 11-12</figref>, it is noted that the process of injection molding is well known in the art and thus will only be described briefly here. In general, injection molding is a manufacturing technique for making objects from a thermoplastic material <b>260</b>. The injection molding process may require the use of a production tooling, commonly referred to as a mold <b>200</b>, and an injection-molding machine, also known as a press <b>210</b>. The mold <b>200</b> commonly comprises at least a first section <b>202</b> and a second section <b>204</b>. The mold <b>200</b> may be constructed in the inverse of the particular shape desired. A press <b>210</b> may hold the mold <b>200</b> closed while a thermoplastic material <b>260</b> such as acrylonitrile butadiene styrene (ABS), polypropylene, polyethylene, or polycarbonate is injected into the mold <b>200</b>. The thermoplastic material <b>260</b> may be formed by melting a resin <b>250</b>. Commonly, the resin <b>250</b> may be in pellet or granule form and melted by heat and shearing forces shortly before injection into the mold <b>200</b>. After injection, the mold <b>200</b> may be cooled and the part extracted. Extraction may be by the use of extractor pins <b>270</b>, air or any method chosen with sound engineering judgment. Injection-molded thermoplastic provides a relatively lightweight object with superior strength and durability in nearly any weather condition. Construction of the mirror assemblies <b>30</b>, <b>40</b> is not limited to the method described herein, and may be constructed using any method chosen with sound engineering judgment.

With reference now to <figref idrefs="DRAWINGS">FIGS. 5-7</figref>, various methods for forming a mirror assemblies <b>30</b>, <b>40</b> according to various embodiments of this invention will now be described. First, the middle portion <b>70</b> may be placed into a mold <b>100</b>. The front portion <b>50</b> may then be formed by inserting a first thermoplastic material <b>102</b> into the mold <b>100</b> on a first side <b>52</b> of the middle portion <b>70</b>. The front portion <b>50</b> may be substantially transparent or clear. The first thermoplastic material <b>102</b> may be a polycarbonate. In another embodiment, the first thermoplastic material <b>102</b> may be any thermoplastic chosen within sound engineering judgment. In a more specific embodiment, the first thermoplastic material <b>102</b> may be inserted into the mold using an injection molding process. In one embodiment, the front portion <b>50</b> adheres to at least a portion of the first side <b>52</b> of the middle portion <b>70</b>. When used with an exterior mirror assembly <b>30</b>, a scratch resistant material <b>54</b> may be applied to at least a portion of the front portion <b>50</b> for use in protecting the front portion <b>50</b> from ice, snow, dirt, and other material that may contact an exterior mirror <b>30</b>. In one embodiment, the scratch resistant material <b>54</b> is a coating that is applied by having the coating flow over at least a portion of the front portion <b>50</b>. In another embodiment, the scratch resistant material <b>54</b> is any material chosen within sound engineering judgment and applied to at least a portion of the front portion <b>50</b>. The back portion <b>90</b> may then be formed by inserting a second thermoplastic material <b>104</b> into the mold <b>100</b> on a second side <b>92</b> of the middle portion <b>70</b>. The front and back portions <b>50</b>, <b>90</b> are thus both in an over-molded structural relationship with respect to the middle portion <b>70</b> when the respective first and second thermoplastic materials set. Further, in the exemplary embodiment, the back portion <b>90</b> is in an over-molded structural relationship with respect to the first portion <b>50</b>. The back portion <b>90</b> may be opaque having any desired color or colors as is known in the art. The second thermoplastic material <b>104</b> may be a polycarbonate. In another embodiment, the second thermoplastic material <b>104</b> may be any thermoplastic chosen within sound engineering judgment. In a more specific embodiment, the second thermoplastic material <b>104</b> may be inserted into the mold <b>100</b> using an injection molding process. In one embodiment, the back portion <b>90</b> adheres to at least a portion of the second side <b>92</b> of the middle portion <b>70</b>. In yet another embodiment, the back portion <b>90</b> may adhere to at least a portion the front portion <b>50</b>. In still another embodiment, the back portion <b>90</b> may adhere to at least of portion of the front portion <b>50</b> and at least a portion of the second side <b>92</b> of the middle portion <b>70</b>. In still another embodiment, the front portion <b>50</b>, the back portion <b>90</b> or a combination of the back and front portions <b>90</b>, <b>50</b> may encompass the perimeter <b>94</b> of the middle portion <b>70</b> and thereby partially or fully seal the mirror assemblies <b>30</b>, <b>40</b>. Encompassing the perimeter <b>94</b> of the middle portion <b>70</b> means substantially surrounding the outside edge of the middle portion <b>70</b> with either the front portion <b>50</b> the back portion <b>90</b> or both the front and back portions <b>50</b>, <b>90</b>. In one embodiment, the front portion <b>50</b> substantially surrounds the perimeter <b>94</b> of the middle portion <b>70</b>. In another embodiment, the back portion <b>90</b> substantially surrounds the perimeter <b>94</b> of the middle portion <b>70</b>. In yet another embodiment, both the front portion <b>50</b> and the back portion <b>90</b> each at least partially surround the perimeter <b>94</b> of the middle portion <b>70</b>. Partially sealing the mirror assemblies <b>30</b>, <b>40</b> means having the front portion <b>50</b> and the back portion <b>90</b> in contact with each other around at least a portion of the perimeter <b>94</b> of the middle portion <b>70</b>. Fully sealing the mirror assemblies <b>30</b>, <b>40</b> means having the front portion <b>50</b> and the back portion <b>90</b> in contact with each other around substantially the entire perimeter <b>94</b> of the middle portion <b>70</b>. In one embodiment, the front portion <b>50</b> and the back portion <b>90</b> form a seam <b>96</b> on the outside surface <b>98</b> of the mirror assembly.

Various embodiments have been described, hereinabove. It will be apparent to those skilled in the art that the above methods and apparatuses may incorporate changes and modifications without departing from the general scope of this invention. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.